Patent application title: APPARATUS AND METHOD FOR CONNECTING A RAIL OR STRUCTURAL MEMBER TO A POST OR OTHER STRUCTURE

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Abstract:

A connector to connect a railing to a post comprising a male bracket that
attaches to the railing and which has a front surface on which is
provided an elongate tenon that widens outwardly from the front surface.
The tenon is tapered from its bottom towards a wider top end, and it also
narrows in thickness from the top end towards the thinner bottom end. The
connector also includes a female bracket that attaches to the post and
which has a front surface in which is provided a slot that widens
inwardly from the front surface. The slot also tapers from a bottom end
towards a wider top end, and it also narrows in thickness from the top
end towards the thinner bottom end. The slot and tenon are complementary
so as to together, providing a snug joint between the brackets when the
tenon is completely received within the slot.

Claims:

1. A connector for detachably connecting an end of a horizontal
longitudinal member to a vertical support member, the connector
comprising: a. a male bracket for attachment to one of said members, the
male bracket defining a first rear surface for abutting the one of said
members and a first front surface opposite the first rear surface, the
first front surface having an elongate tenon thereon that widens
outwardly from the first front surface, the tenon further being tapered
from a first tenon end towards a wider second tenon end, and the tenon
further narrowing in thickness from the second tenon end towards the
thinner first tenon end; b. a female bracket for attachment to the other
of said members, the female bracket defining a second rear surface for
abutting the other of said members and a second front surface opposite
the second rear surface, the second front surface defining a slot therein
that widens inwardly from the second front surface, the slot further
being tapered from a first slot end towards a wider second slot end, and
the slot further narrowing in thickness from the second slot end towards
the thinner first slot end, wherein the second slot end extends to an
edge of the female bracket to define a slot opening; and c. wherein the
slot and the tenon are complementary such that they provide a snug
connection between the male bracket and the female bracket when the tenon
is completely inserted into the slot.

2. The connector as claimed in claim 1 wherein the tenon and the slot are
in full engagement when the tenon is completely received within the slot.

3. The connector as claimed in claim 1 wherein the tenon has tenon sides
that are angled such that the tenon gradually widens outwardly from the
first front surface, and the slot has slot sides that are angled such
that the slot gradually widens inwardly from the second front surface.

4. The connector as claimed in claim 1 further including a plurality of
projections on one or both of the first rear surface and second rear
surface wherein said projections are sized to grip the material of one or
both of said members.

5. The connector as claimed in claim 4 further including an extension
from the first front surface of the male bracket that overhangs the edge
of the female bracket to conceal the slot opening when the male bracket
and female bracket are connected thereby providing a fully blind joint
there between.

6. The connector as claimed in claim 5 wherein the edge of the female
member defines a bore and the extension defines a hole that aligns with
the bore, and wherein the hole and the bore are adapted to receive a
fastener for securing the extension of the male bracket to the edge of
the female bracket.

7. The connector as claimed in claim 4 wherein said brackets are sized
such that when connected to each other they conform to the external
dimensions of the end of the horizontal member thereby continuing the
shape of the longitudinal member to the support member.

8. The connector as claimed in claim 1 further including an extension
from the first front surface of the male bracket that overhangs the edge
of the female bracket to conceal the slot opening when the male bracket
and female bracket are connected thereby providing a fully blind joint
there between.

9. The connector as claimed in claim 8 wherein said brackets are sized
such that when connected to each other they conform to the external
dimensions of the end of the horizontal member thereby continuing the
shape of the longitudinal member to the support member.

10. The connector as claimed in claim 8 wherein the edge of the female
member defines a bore and the extension defines a hole that aligns with
the bore, and wherein the hole and the bore are adapted to receive a
fastener for securing the extension of the male bracket to the edge of
the female bracket.

11. The connector as claimed in claim 8 further including a plurality of
projections on one or both of the first rear surface and second rear
surface wherein said projections are sized to grip the material of one or
both of said members.

12. The connector as claimed in claim 1 wherein the first front surface
of the male bracket is angled relative to the first rear surface to
provide an angled connection between the longitudinal member and the
vertical support member.

13. The connector as claimed in claim 1 wherein the second front surface
of the female bracket is angled relative to the second rear surface to
provide an angled connection between the longitudinal member and the
vertical support member.

Description:

BACKGROUND

[0001] In the field of railing construction and particularly outdoor wood
railings for porches, balconies, decks and the like, there is a common
problem of connecting wooden structural rail members to posts or super
structures such as a wall of a building so that direct wood on wood
contact is eliminated, the connection surpasses functional load
requirements imposed by building codes, and it does so ideally by
substantially or completely concealing the fasteners. Applications of
suitable connections may include but are not limited to rail members,
stair stringers or even balusters to rail members.

[0002] Wood is a very popular material to build outdoor railings and other
structures; both in terms of its preferred aesthetic qualities and its
affordability. However, as a natural material, wood is susceptible to
premature rot and deterioration if subjected to continuous moisture.
Common areas where rot can set it are nail or screw penetration holes on
flat surfaces. But exposed end cuts of lumber are even more susceptible
to moisture damage. This is because an end cut of dimensional lumber
exposes the open ends of the grain of the wood. The grain has a natural
capillary structure that aids the tree when it is living, but which can
be detrimental to wooden structural members if exposed to moisture. Water
is sucked up by the end grain thereby creating an optimal environment for
rot and mould to establish itself and eventually destroy the integrity of
the wood.

[0003] To combat this, it is recommended to build with wood in such a way
that the porous end cuts of wood members are not exposed to moisture.
Reducing areas of wood to wood contact is one of the first lines of
defense that can be employed to extend the life of any wood structure or
railing. This is simple enough to do in some types of construction but is
more difficult to do when building wood railings because the horizontal
rail members must connect directly with wood posts. It is at these
contact points where moisture can reside because of lack of air flow to
promote evaporation.

[0004] There is another common problem beyond wood on wood contact that is
associated with building wood railings or stairs and it pertains to the
challenges of securing such things as a rail member or stair stringer or
any structural member that is laterally opposed in some way to another
securing surface. An example is where rails laterally connect to posts,
but is not limited to this situation. Rails are generally oriented at
90° to posts. In the case of stair rails or stair stringers, the
angle is usually somewhere between 30°-35°. Furthermore,
these angles can become compounded if the direction of the vertical plane
of the rail sections mate with corners at 45° or 22.5°,
which are common in the field.

[0005] In both cases, the union between post and rail is potentially weak
because of the very small surface contact area between the post and the
rail and because of the long arm which the rail represents. Although
rails are connected at both remote ends to posts and does not function as
a lever arm, they nonetheless must successfully transfer the entire
lateral load that may be inflicted upon a guard rail without failing.
They are a crucial component of any guard rail.

[0006] Common methods used in the field to secure post and rails are
"toe-nailing" techniques where nails or screws are driven through side
walls of a rail member near the remote end at a 45° angle and then
into the mating surface of the post. This is the crudest means of
connection.

[0007] Another problem that has not yet been adequately solved is one of
aesthetics. There is a desire among homeowners and builders to create the
most attractive looking railing connection means as possible. Brackets
and connectors which are highly visible and tend to wrap completely
around the horizontal rail members are generally less appealing to most
people. It would be very desirable, to have a connector which would be
completely hidden from view between the end of the rail members and the
post while still surpassing all performance and safety standards.

[0008] Various connecting devices have been developed, which are
referenced more thoroughly in the following discussion concerning the
prior art, that permit an easier means of attaching post and rail than
simple "toe-nailing" techniques and also act as an intermediary surface
to prevent direct wood on wood contact.

[0009] While it is a simple task to create a connector which provides
adequate strength, it is a much more challenging task to devising a
solution which performs well and is completely concealed from view. And
with such a concealed connector, it would also be desirable if it would
have features that made it easy to precisely locate said connectors onto
opposing posts so that an entire assembled railing section could be
quickly dropped into position between posts. As will be shown, none of
the prior art offers a completely or substantially concealed means of
connecting the post and rail, exterior stair stringer to ledger or the
like (to name a few possible applications), while also providing a simple
and reliable means of accurately locating a series of four connectors on
two opposing posts that will easily allow a completed railing assembly to
precisely mate and connect with them.

[0010] There are numerous examples in the prior art of railing mounting
brackets. One of the earliest forms of prior art is U.S. Pat. No.
4,280,686 issued to D. Wack which is a one piece device comprising a
strip of sheet metal folded to create a lower tab and a horizontal ledge
upon which a 2×4 can rest. The strip continues vertically between
the end of the 2×4 and the post, extending just above the top
surface of the 2×4. Three nails or screws can be driven into the
end of the 2×4 from the post face side and a single fastener can be
screwed from the 2×4 side through the lower and upper exposed tabs
into the post.

[0011] The Wack device is purely utilitarian and serves as an intermediary
material through which fasteners may pass at 180 degree opposition to
each other and into both post and rail. The upper and lower fasteners
remain visible. There is no decorative profiling or shaping of the
device, although this could easily be done were the device to be made
through an injection molding process. The fasteners are positioned in
shear relative to all forces that are imposed on the railing.

[0012] This concept has evolved over the years to include the use of the
toe-nailing techniques discussed earlier as seen in U.S. Pat. Nos.
5,160,211 and 5,419,649 to T. Gilb, which teach the use of a device that
permits easy toe-nailing into the post and the underside of a rail that
completely covers the top of a post or abuts to the side of a post. The
fasteners are also positioned in shear relative to the forces imposed on
the rail.

[0013] Over time refinements to this concept continued and are exemplified
in the design characteristics of U.S. Design Pat. Nos. D549,555,
D523,325, and D532,679 issued to Ignagni. The Ignagni devices build upon
the notion of providing a flat planar surface and incorporates a built up
radiused perimeter edge that completely encircles the end of a 2×4
rail on all four side, three sides or two parallel sides. The radiused
edges are significant enough to allow for angled and counter sunk holes
for screws to pass through and penetrate the post at an angle utilizing
the "toe-nail" fastening technique but with better aesthetic results. The
countersinking hides all of the screw except the top of the head. In this
way the raised edges, being proud of the planar surface of the device,
provide some lateral stability to the post and rail connection while
improving appearance and promoting a drier post to rail connection.

[0014] The Stoltzfus device, in U.S. Design Pat. No. D553,479, varies from
the previous examples by providing a concave apparatus for a T shaped
rail where either a one piece rail formed into a T can be inserted into
the concave opening or two rectangular shaped members could be inserted
inside. The Stoltzfus device suggests a design that seems intended for a
proprietary molded rail system but the concept could be extended for wood
rails also. The Stoltzfus design extends the concept of raised radius
edges to a greater distance along the length of the rails.

[0015] In all of this prior art, one sees a progression from that of the
Wack device which uses a thin strip of metal that generally runs
vertically in line with the periphery of the vertical walls of the
2×4 rail, with upper and lower tabs to extend beyond the periphery
of the horizontal walls of the rail to the subsequent devices and designs
that extend beyond and then upwards along all peripheral walls of the
rails to various degrees.

[0016] The Stoltzfus device contemplates or could be implied to
contemplate the potential use of a second rail member that would be
secured flat on top of the edge of a bottom 2×4 to create the
common "T" profile of a wood top rail configuration. It would be possible
to achieve this "T" configuration using only one of the Ignagni three or
two sided devices for the 2×4 oriented on its edge. A flat
2×4 could then be set on top of the other 2×4. It would lay
flat and be screwed down onto the edge of the lower 2×4 and then
traditionally toe-nailed to the post. This top rail would then have
direct wood to wood contact and be at risk of premature deterioration
from water damage. The Ignagni device could not be used for the flat
capping 2×4. Whereas an ideal device that would sit entirely within
the peripheral walls of a 2×4 could also be used for securing flat
top rail 2×4s to posts in the common "T" configuration.

[0017] Of these devices only the relatively recent device described in
European Patent 1288508 issued to Harrer comes close to doing what an
ideal device would do. The Harrer device uses a tongue and groove or a
dove tail like pair of connectors with particular application for
securing structural members of timber frame buildings although it could
be applied to lighter structures. Given that the purpose of the device is
to ultimately support many tons of weight, all aspects of it are designed
to maximize load performance and preserve the precision of the
connection.

[0018] The two connectors are able to fit within the peripheral walls of a
member and therefore provide the aesthetic demands many people desire.
But the typical installation is to form a cavity with a router in one
surface and set one of the connections tightly within the cavity and
screw it into place. The cavity walls serve to secure the connector so
that it can not move while the numerous screws are being installed in a
toe-nail fashion.

[0019] Given the prescribed toe-nail installation of the screws through
the connector, which is intended to provide the maximum shear resistance
in order to help achieve the desired high structural loads, the connector
would be very hard to keep in a stationary position without the cavity,
as screws driven at such an angle often veer unpredictably until they
catch enough material to set their path. And once a toe-nailed screw
reaches its final maximum depth it is common for the screw to pull the
assembly transversely across the planar surface. This effect is
accentuated the softer the wood material is. Compensating for this
requires carefully and slowly alternating the driving of opposing screws
so as to equalize the pulling effect and maintain the connector in a
stationary position. This is overcome when the connector is set into a
cavity.

[0020] However this methodology, while shown to be effective in connecting
heavy structural perpendicularly oriented members is not the optimal
solution for lighter weight structures such as wood guardrails or fence
panels as an example for two primary reasons.

[0021] Firstly, the process of cutting a receiving cavity is time
consuming and demands a higher level of skill particularly in the use of
high powered plunge routers and accurate placement of immoveable
templates to ensure precision of the cavity dimensions. Time and skill
implies higher costs. That being said, the construction of a timber frame
structure implied by the Harrer device is invariably encompassed in a
larger and more expensive construction project than a comparatively
smaller outdoor deck with wood rails. It is foreseeable that the
increased costs associated with Harrer device, installation procedures
and technical skill of the tradesman required, could be more easily
subsumed within the overall construction budget of a larger building
project. However the opposite holds true for the average homeowner or
tradesman planning to build a small lightweight structure like a deck
railing quickly and affordably. The Harrer device and methodology renders
itself too expensive for all but the most affluent customers in the
market and thus not a solution for the mass do it yourself market.

[0022] Secondly, an optimal installation method for quickly connecting
railing section panels between posts, that being two pre-built horizontal
rail members connected together by balusters perpendicularly between
them, so that the complete and finished railing section may be fitted
accurately in place whereby the male shaped connectors affixed to the
ends of the horizontal rail members can be fitted into their female
counterparts against the posts, can not easily be achieved using the
Harrer device. This is because of the necessity to very accurately locate
the cavities within the posts to receive the female part of the connector
and to ensure that they in turn are in perfect spatial relationship to
the multiple awaiting male connectors of the railing section. This is
critical because the design of the tongue and groove of the Harrer device
fits so precisely together and necessarily so in order to perform at the
higher load standards envisioned for the device as a structural frame
connector. If any of the female connectors attached to the posts were out
of position even slightly, then its corresponding male part would not fit
or seat itself fully. To force the anomalous connector together would
either pull the balusters apart from the top and bottom rails or not
permit the connector to seat fully with its male counterpart leaving it
sitting proud or high in the groove because the balusters could not be
compressed.

[0023] The Harrer device attempts to alleviate this issue somewhat by
utilizing a tapered "lead in" shape in the male and female tongue
portions along a singular planer dimension which will be subsequently
explained in greater detail and shown why this is not an optimal solution
for use in installing lighter weight structures, panels or railing
sections.

[0024] The Harrer device performs its specific function of maximizing load
resistance from many axes largely because of its precision according to
company literature. The Harrer device is therefore designed so that the
female channel is widest at the opening and then quickly tapers inward
before becoming straight. The taper is along one dimensional plane
only--across the connectors wide but flat surface. Thus to engage the
connectors, the lateral rail or frame member must be in perfect proximity
to the female connector along the dimensional plane corresponding to the
longitudinal axis of the lateral member. In other words, it must be
pressed up close against the post and awaiting female connector whereas,
some latitude is afforded along the connector's lateral plane or second
dimensional plane. In simpler terms, sideways movement of the lateral
rail is permitted because of the taper and assists in allowing the tongue
and groove to align and catch. This uni-planar dimensional taper may
provide the performance characteristics desired by users of the Harrer
device but renders it difficult to use in the application of installing
lighter weight pre-built panels such as railing and fence sections as
described above.

[0025] Given the weight of large timber members and the fact that they are
likely required to be held overhead in precise alignment with a hoist or
crane during installation, it is much less likely that multiple heavy
timbers built in advance into assemblies would or could be easily
positioned so accurately as to account for the precise simultaneous
alignment of at least four pairs of mating connectors as would be the
case with a lighter weight rail section with top and bottom rails and
filled with balusters between. The latter example is not the application
that the Harrer apparatus effectively addresses.

[0026] Having shown the strengths and weaknesses of the Harrer device, a
discussion of the need for an ideal device and methodology in light of
the Harrer device's limitations will now follow.

[0027] If one contemplates using the Harrer device in the day to day
installation of railing assemblies, numerous challenges come to mind. In
order to secure a timber with the

[0028] Harrer device the connectors must be fastened to the remote ends of
a timber and the entire member must be fitted in to place to determine
where the other half of the each connector must be located on the
opposing surfaces. Perhaps one could calculate this with precise and
careful measurements. In either case because of the heavy weights
involved it is certain to require mechanical lifting assistance and
precision just for a single timber which has only two remote ends to be
connected. Little forgiveness if any is afforded in this apparatus for
precisely the reason that it can be used to support such heavy loads.

[0029] If one thinks of the installation of a railing assembly where
connectors are fixed on the four remote ends of the rail members and an
installer lifts the assembly into position, all four of the connectors
must align with the receiving opening of their mated connector. The
Harrer device allows room for assisting alignment of the tongues along a
single lateral dimensional plane; the flat planer width of the connectors
by virtue of the tapered opening in the groove and so in order for all
four connectors to mate and slide easily and completely together very
close tolerance is required. This imposes a higher standard of skill,
effort and accuracy for a person building a rail assembly even if the
paired connectors that are secured to opposing posts were initially
perfectly positioned. If the rail assembly has any looseness or "give" it
could be enough to move any one of the four connectors off of perfect
alignment and make if more difficult for a user to drop the rail assembly
in place.

[0030] One way to try to address this if using the Harrer device would be
to "dry-fit" the assembled rail section between posts and then precisely
mark with a pencil the locations of the where the post connectors should
be set for final resting position. The assembly could be removed from
between the posts. The connectors pulled apart and the portion then
relocated exactly on the post where it was marked. Screwing those
connectors to the post would require precision. If the screws pulled or
pushed the connector into a final resting location that is not exactly as
marked, it would result in an imperfect re-joining of the connectors on
the four remote ends of the rails in the assembly. The alternative would
be to cut cavities into the post wall to retain the connector, as is
taught by Harrer.

[0031] For a person skilled in the art of building railing or deck
building, a myriad of issues arise which must be dealt with to maintain
exact alignment for this kind of a system to ever be user friendly in the
field.

[0032] An ideal device for the applications common to building lighter
weight structures such as deck railing would provide for a means of
marking exact connector locations, preferably by physical impression or
registration onto the flat planar surfaces of the opposing posts or
surfaces and providing great leeway for each pair of mating connectors to
engage laterally and more importantly, longitudinally; for imprecise
movements or minor errors in the building of the rail section so that all
four connectors would more easily align and then pull together for a
final firm fit.

[0033] In summary, none of the prior art devices discussed herein, other
than Harrer's apparatus, efficiently address the issue of keeping the
ends of the rails as dry as possible at the point of contact on the post
or of providing the most concealed fastener system possible; concealed by
virtue of being situated entirely behind the end of a rail and within the
peripheral of the walls of the 2×4 rail. Nor do they completely
hide the fastening means from view. Nor do they lend themselves to a
simpler method of installation that can account for the typical margin of
error in measurement and building.

[0034] An ideal device that would address these functional needs and
installation challenges would represent the highest aesthetic and
practical installation standards possible and with a simpler, faster
installation method, would also reduce user costs associated with time
and skill thus giving is more appeal as a mass market solution. In the
case of the Harrer device it is designed to carry extreme structural
loads. Therefore both its design and installation method require high
levels of precision rendering it more difficult and less practical to
install in the way that builders and homeowners commonly install lighter
structures such as completed rail section assemblies with balusters.
Among theses devices and methods there is significant room for
improvement. A greatly improved aesthetic appearance can be attained by
virtue of utility and design attributes which will be presented by the
ideal apparatus and its easier method of use and installation.

[0035] Therefore there is a need for a hidden rail to post connector
device and method for constructing wood railings and the like that
maximizes speed and simplicity of installation, standards of appearance,
and improves the ability for the post and rail to remain drier, longer
and thereby extend the useful life of the railing. Furthermore there is a
need for a device and method that makes it easier for a user to
accurately mark and locate multiple pairs of connectors in a fixed
relationship to opposing mating surfaces. Lastly, there is a need for
such a device or method to compensate for a reasonable margin of error or
imperfection so that multiple pairs of connectors can be easily and
simultaneously aligned and inserted into their counterpart connectors
during installation.

SUMMARY OF THE INVENTION

[0036] In some aspects the present invention provides a connector for
detachably connecting an end of a horizontal longitudinal member to a
vertical support member, the connector comprising: a male bracket for
attachment to one of said members, the male bracket defining a first rear
surface for abutting the one of said members and a first front surface
opposite the first rear surface, the first front surface having an
elongate tenon thereon with angled tenon sides such that the tenon widens
outwardly from the first front surface, the tenon further being tapered
from a first tenon end towards a wider second tenon end, and the tenon
further narrowing in thickness from the second tenon end towards the
thinner first tenon end; a female bracket for attachment to the other of
said members, the female bracket defining a second rear surface for
abutting the other of said members and a second front surface opposite
the second rear surface, the second front surface defining a slot therein
with angled slot sides such that the slot widens inwardly from the second
front surface, the slot further being tapered from a first slot end
towards a wider second slot end, and the slot further narrowing in
thickness from the second slot end towards the thinner first slot end,
wherein the second slot end extends to an edge of the female bracket to
define a slot opening; and wherein the slot and the tenon are
complementary such that they provide a snug connection between the male
bracket and the female bracket when the tenon is completely inserted into
the slot.

[0037] The term "tenon" as used herein is in accordance with its
dictionary definition, namely, a projecting member on a piece of material
for insertion into a mortise to make a joint. The terms "tongue" or
"tang" are sometimes used interchangeably with "tenon". The term
"mortise" as used herein is also in accordance with its dictionary
definition, namely, a slot into which some other part of an arrangement
of parts fits or passes, especially, a cavity cut into a piece of
material to receive a tenon. The terms "slot" and "socket" are used
interchangeably with "mortise".

[0038] In some embodiments, the connector may include a plurality of
projections on one or both of the first rear surface and second rear
surface wherein said projections are sized to grip the material of one or
both of said members.

[0039] In some embodiments, the connector may include an extension from
the first front surface of the male bracket that overhangs the edge of
the female bracket to conceal the slot opening when the male bracket and
female bracket are connected thereby providing a fully blind joint there
between. In some embodiments, the edge of the female member defines a
bore and the extension defines a hole that aligns with the bore, and
wherein the hole and the bore are adapted to receive a fastener for
securing the extension of the male bracket to the edge of the female
bracket. In some embodiments, the brackets may be sized such that when
connected to each other they conform to the external dimensions of the
end of the horizontal member thereby continuing the shape of the
longitudinal member to the support member.

[0040] In some embodiments, the first front surface of the male bracket is
angled relative to the first rear surface to provide an angled connection
between the longitudinal member and the vertical support member. In some
embodiments, the second front surface of the female bracket is angled
relative to the second rear surface to provide an angled connection
between the longitudinal member and the vertical support member.

[0041] The present invention provides a connector that can fit completely
within the periphery of any rail member. It requires no routered cavities
with a mounting surface to prevent the connectors from moving from their
intended positions as they are secured to opposing surfaces. It
physically marks or registers its final location on a surface so it may
be moved, separated and then accurately repositioned its exact original
location prior to fixation. It secures itself reliably as screws are
driven into place. The connector of the present invention provides a
cleaner, sleeker appearance with only a shadow like reveal between rail
and post. The fact that the device does not extend beyond the peripheral
walls of the rail member, provides the highest aesthetic qualities
because the fasteners would be completely hidden from view. A device that
is equal to or marginally smaller than the periphery of the 2×4
walls, would therefore fully expose the peripheral walls near the
terminus of the 2×4 rail and allow air to flow unimpeded around all
four walls hastening and promoting water evaporation. The device would
provide sufficient distance as an intermediary material between post and
rail preventing wood on wood contact.

[0042] A device which incorporates the characteristics of a male tenon and
female mortise, slot or channel that can be made into a blind
configuration entirely hides from view the working aspects of the joint.
Furthermore, and to the benefit of installers, a device incorporating
such a joint which is tapered in two adjacent and perpendicular
dimensional planes would provide a degree of latitude and margin of error
for users while simultaneously aligning multiple remote connectors of an
assembly. This is an aspect which would improve and render more efficient
the installation of railing sections or other like assemblies.

[0043] In summary such a device would represent a significant advancement
in this field and have many desirable characteristics for longevity and
enhanced appearance. It would also represent a movement away from the
direction that the prior art has tended to teach which is towards
connectors that wrap further around the side walls of the rail member and
only employing decorative designs to improve the appearance rather than
fitting inconspicuously behind the end cut of the rail and utilizing
concealed means of connecting.

[0044] In order to address some of the shortcomings of the prior art there
is provided a concealed post to rail connecting apparatus which can act
as a fastening union between post and rail that is itself largely hidden
from view behind the end of a lateral rail member and which also hides
any fasteners inside itself. It is concealed in terms of a) being
physically hidden behind the end of a rail member as opposed to wrapping
around its side walls; b) providing virtually complete concealment of the
means by which parts mate together; and c) completely conceals all
fasteners within the bodies of the parts, save and except for an optional
flat head top screw to prevent uplift--an atypical load force for
guardrails. And in order to render the installation of complete rail
sections consisting of at least two rail members with perpendicularly
oriented balusters, it is necessary to include in the device a means of
allowing for greater leniency for simultaneously aligning the multiple
mating parts of the device along lateral and longitudinal planar
dimensions and thus reduce the precision required by the user to engage
them all at the same time during an installation.

[0045] Accordingly, the preferred apparatus is comprised of at least two
parts. For ease of description the first part will be referred to as the
male bracket, which in illustrated embodiment is the rail bracket, and
the second part as the female bracket, which in the illustrated
embodiment is the post bracket. Together they form the complete railing
connector. Each bracket is secured separately to post and rail by screws
through countersunk holes in each bracket. The brackets then mate
securely together by means of a male tenon and complementary female slot
to create a strong joint.

[0046] In some embodiments, from a front view of the mating surface, a
female opening in the shape of a narrow elongated trapezoid is defined on
the flat front surface of the post bracket with the wide base at the top
and the narrow end of the trapezoid shape near the bottom of the bracket.
The aperture then slopes outwardly inside the body of the post bracket
towards the exterior walls and resembles a chamfered shape. From a front
view of the rail bracket a reciprocal narrow male elongated trapezoid
shape is defined and is raised or elevated above a lower planar surface.
The sides of the male member slope downward from the top surface of the
male member in a chamfered shape towards the lower planar surface. The
male and female shapes are tapered along two dimensional planes and
observable when viewing the rail bracket from the front and side of its
length so that it is easier for them to align and mate when used in the
field. The male and female portions of the brackets slide parallel
together in order to secure itself. The result is a very rigid and
concealed union which resists very high shear forces.

[0047] The joint created is referred to as "blind" because the male member
shape of the rail bracket stops short of running the entire length of the
connector as does the female channel of the post bracket. The post
bracket has a flat bottom shoulder or shelf like area situated near the
tapered end of the female aperture near the end of its length but well
within its defined peripheral walls thus allowing the male shape to
finally seat itself on the shoulder and hiding itself within the post
bracket.

[0048] Counter bored through holes for screws are located along the
longitudinal center line and in an offset placement pattern of the
brackets. Sufficient clearance for the heads of each screw is provided so
that the brackets may slide freely into their final resting place and
completely concealing the internal fasteners from view. The screws are
oriented in shear against the lateral forces that are imposed upon the
rail during its useful life.

[0049] Some embodiments comprise post and rail brackets that have
identical perimeter shapes and appear as one when they slide together.
The perimeter would at most, be equal to the periphery of the walls of
the 2×4 rail. The benefit of having the perimeter of the joined
railing connectors equal to but not larger than the peripheral size of
the 2×4 member is that a single form of connector can then be used
for rails oriented vertically on their edge as is common in fence and
rail top and bottom rail members and as to secure a flat oriented
2×4 on top of a 2×4 on edge to create a "T" formation unlike
anything else in the prior art. These "T" formations of rail members is
commonly seen in the field of wood guard rails but sometimes on fences as
well.

[0050] It will be readily apparent to those skilled in the art that the
present invention can be adapted easily for use with stair rails and
stair stringers that have a longer diagonal cut surface that mates with a
post. It will also be apparent that the post connector can be adapted to
adjust to angled corners, such as for example 45° and 22.5°
corners that are common in the field. In such cases, the back side of the
post bracket would be built up to account for the angle so that the front
face of the post connector would be perfectly aligned with the rail
connector. In this way the end of the rail member can easily be cut off
straight at 90° to the length of the gap between posts without
complication and the resultant railing section aligned parallel to the
plane of the railing system.

[0051] In some embodiments, rather than having a unique post bracket part
as referred to above with an integral 45° or 22.5° surface
on the backside of the post bracket, a third unique part may be provided
in either 45° or 22.5°. The third part would fit inside the
cavity at the back of the post bracket thus making it quickly adaptable
for using in corner applications. It is understood by those skilled in
the art that either a unitary piece or an angled insertion piece as
suggested would achieve the same result.

[0052] Referring to the 45° or 22.5° embodiments, either as
a unitary part of the back side of the post connector or as an
independent insertable part, it would be secured to the post wall by the
same screws that pass through the counter bored holes in the female
shaped channel or aperture of the post bracket. However, additional
counter bores would be located along the long side of the post connector
and angled insertable part. Flat head screws would pass through and seat
within the counter bores permitting further means of attachment between
the post connector and the post.

[0053] The rail bracket has a horizontal flange on one end that overlaps
the opposing mating surface of the post bracket once the dovetail members
are slid together. A small counter bored through hole is located in the
center of the flange and accepts a flat head screw which when inserted
secures the rail and post connector so as to prevent separation of the
parts.

[0054] The flat surfaces of the post and rail brackets that contact either
the post or end of the rail may be provided with a plurality of small
projections such as gripping cones at various locations. The cones are
hard and yet short enough to impress into soft or medium density wood
fiber or similar material in order to help keep the parts secure and
immoveable during the installation phase when screws are at risk of
veering along grain lines.

[0055] The mid span of the top and sides of the post and rail brackets are
also defined by a positive or negative embossed line near the peripheral
edge that serves to identify the center of the railing connector and
provide a reference point by which a user can easily make a pencil mark
on the mating surfaces of the post or rail. This allows the connectors to
be separated and individually secured to opposing mating surfaces but in
perfect reference to each other for re-connection.

BRIEF DESCRIPTION OF DRAWINGS

[0056] For a better understanding of the present invention and to show
more clearly how it may be carried into effect, reference is made by way
of example to the accompanying drawings in which:

[0057] FIG. 1 is a perspective view of a first embodiment of the railing
connector device in accordance with the present invention and shown
attached to post in a railing application;

[0058]FIG. 2 is a perspective view of a second embodiment of the railing
connector device in accordance with the present invention shown attached
to a post forming an angled corner in a railing application (45°
angle shown here);

[0059]FIG. 3 is a perspective view of the railing connector device in
FIG. 1 from behind with the post not being shown;

[0060]FIG. 4 is a front elevation view of the railing bracket comprising
part of the rail connector shown in FIGS. 1 and 3;

[0061]FIG. 5 is a rear elevation view of the post bracket comprising part
of the rail connector shown in FIGS. 1 and 3;

[0062]FIG. 6 is an exploded rear fragmentary perspective view of the post
bracket in FIGS. 1 and 3;

[0063] FIG. 7 is an exploded front fragmentary perspective view of the
post bracket in FIG. 1 and FIG. 3;

[0064] FIG. 8 is a rear perspective view of the rail bracket in FIG. 1 and
FIG. 3;

[0065]FIG. 9 is front perspective view of the rail bracket in FIG. 1 and
FIG. 3;

[0066]FIG. 10 is a side elevation cross sectional view of the rail
connector connecting a rail to a post;

[0067] FIG. 11 is a side front perspective view of the 22.5° wedge
bracket;

[0068]FIG. 12 is a side and rear perspective view of the 22.5°
wedge bracket;

[0069]FIG. 13 is a perspective view of the second embodiment of the
railing connector in a corner angle application from the rear of the
22.5° wedge bracket, post bracket and rail bracket;

[0070]FIG. 14 is a perspective view of the second embodiment of the
railing connector in a corner angle application from the rear of the rail
bracket, post bracket and the 22.5° wedge bracket with all
fasteners;

[0071]FIG. 15 is a side front perspective view of the 45° wedge
bracket;

[0073] FIG. 17 is a perspective view of the second embodiment of the
railing connector in a corner angle application from the rear of the
45° wedge bracket, post bracket and rail bracket;

[0074] FIG. 18 is a perspective view of the second embodiment of the
railing connector in a corner angle application from the rear of the rail
bracket, post bracket and the 45° wedge bracket with all
fasteners;

[0075] FIG. 19 is a top view of a common 90 degree corner configuration of
posts and rails connected by the railing connector;

[0076]FIG. 20 is a top view of a 45° corner configuration of posts
and rails connected by the railing connector;

[0077]FIG. 21 is a top view of a 22.5° corner configuration of
posts and rails connected by the railing connector;

[0078] FIG. 22 is a side elevation view along the length of the railing
bracket;

[0079]FIG. 23 is a cross sectional view along the length of the post
bracket;

[0080]FIG. 24 is a combination cross sectional view of the railing
bracket across the lower portion of the male member tenon and a top view
of the post bracket across the upper portion at the opening of the female
channel depicting the size difference of the mating parts at the moment
of engagement;

[0081]FIG. 25 is a perspective view of a completed rail assembly fitted
loosely between posts and resting on spacers;

[0082]FIG. 26 is a perspective view of a completed rail assembly and
exploded fragmentary perspective view of rail brackets to be secured
prior to being mated with post brackets attached to posts; and

[0083] FIG. 27 is perspective view of a complete rail assembly secured
into final position by rail connectors to opposing posts.

DETAILED DESCRIPTION

[0084] For the purposes of promoting an understanding of the principles of
the invention reference will now be made to the exemplary embodiment
illustrated in the drawings, and specific language will be used to
describe the same. It will nevertheless be understood that no limitation
of the scope of the invention is thereby intended. Any alterations and
further modifications of the inventive features illustrated herein, and
any additional applications of the principles of the invention as
illustrated herein, which would occur to one, skilled in the relevant art
and having possession of this disclosure, are to be considered within the
scope of the invention.

[0085] Referring to FIGS. 1-9, and 22-24, there is depicted an embodiment
of a connector in accordance with the present invention, which in the
illustrated embodiment is a railing connecter 3 particularly suited to
connecting horizontal railings to vertical supports. The connector may
also be used for other applications as will be apparent to persons
skilled in the art upon reading the disclosure herein. Connector 3
comprises a male bracket such as rail bracket 4, and a female bracket
such as post bracket 5. The rail bracket 4 and post bracket 5 mate
together to provide the completed railing connector 3.

[0086] The rail bracket 4 has a horizontal extension 10 which overlaps the
top edge 13 of the post bracket 5 when the parts are fully mated. A
counter bore hole 20 is located in the extension 10. In some embodiments,
the post bracket 5 may be modified to form any desired angle including
the most commonly used 45 and 22.5 degrees.

[0087] A third part may be used that forms a wedge shape at the desired
angle and can fit together with the post bracket to adapt the completed
railing connector for desired angled or corner applications. This part
will be described further on in FIGS. 11-18. The post bracket 5 is
secured to the face of any planar surface but most commonly a post 1 and
the rail bracket 4 is secured to another planar surface of transverse
oriented member but most commonly an end of a wood rail 2.

[0088] Preferably, the brackets 4 and 5 are sized such that when connected
to each other to provide the complete connector 3 they conform to the
external dimensions of the end of the rail (or horizontal member) thereby
continuing the shape of the rail to the post (or support member). Thus,
the complete railing connector does not extend beyond the peripheral
walls of the rail member and preferably slightly within the walls in
order to provide a desired aesthetic appearance. The railing connector 3
also creates a space between the two mating surfaces of post 1 and rail 2
in order to eliminate wood to wood contact. Embossed or impressed lines 7
formed into the post bracket 5 and rail bracket 4 provide a user with the
ease of marking the exact locations of these line on both the rail and
post mating surfaces. The benefit of this will be explained further in
this description.

[0089] Referring to FIGS. 4 and 5 there are front views of the rail
bracket 4 and post bracket 5 respectively. The rail bracket 4 depicts the
rectangular shape of the sides of the bracket, which is identical for the
post bracket 5. The extension 10 is also shown as is the tapered shape of
the tenon 11. In addition the rail bracket 3 can be oriented to secure
rail members 2 that have their edge facing upwards or to secure rail
members that are oriented flat and have their edges facing horizontally.
The wider opening or throat 31 of the slot 17 of the post bracket 5 is
also shown.

[0090] Referring to FIGS. 4, 8, 9, 22 and 24, rail bracket 4 defines a
rear surface 81 that abuts the end of the rail 2, and an opposite front
surface 46 on which is provided an elongate tongue or tenon 11. The tenon
11 is tapered from a first tenon end or bottom end 35 towards a wider
second tenon end or top end 34. The sides 82 of the tenon 11 are angled,
as best shown in FIG. 24, such that the tenon 11 gradually widens or
flares in cross section outwardly from the front surface 46. Furthermore,
as best shown in FIG. 22, the tenon 11 narrows in thickness from the
thicker top end 34 towards the thinner bottom end 35.

[0091] As an alternative to the gradual widening of the tenon outwardly
from the front surface, the tenon may be of uniform cross sectional width
except that a lip or flange portion may be provided remote from the front
surface. Thus, the tenon can be said to widen outwardly, whether or not
the widening is gradual as in the case of the illustrated embodiment or
abrupt as in the case of a lip or flange remote from the front surface
46.

[0092] Referring to FIGS. 5-7, 23 and 24, post bracket 5 defines a rear
surface 66 that abuts the post 1, and an opposite front surface 58 in
which is provided a mortise or slot 17 that is complementary to the tenon
11. The slot 17 is tapered from a first slot end or bottom end 33 towards
a wider second slot end or top end 31. The sides 83 of the slot 17 are
angled, as best shown in FIG. 24, such that the slot 17 gradually widens
or flares in cross section inwardly from the front surface 58.
Furthermore, as best shown in FIG. 23, the slot 17 narrows in thickness
from the thicker top end 31 towards the thinner bottom end 33.

[0093] As an alternative to the gradual widening of the slot inwardly form
the front surface, the slot may be of uniform cross sectional width
except that a wider channel portion may be provided remote from the front
surface sized to accommodate the wider lip or flange portion of a
complementary tenon. Thus, the slot can be said to widen inwardly,
whether or not the widening is gradual as in the case of the illustrated
embodiment, or abrupt as in the case of a channel portion remote from the
front surface 58.

[0094] The slot 17 and the tenon 11 are complementary, analogous to a
sliding dovetail joint, such that they provide a snug connection between
the rail bracket and the post bracket when the tenon 11 is completely
inserted into the slot 17.

[0095] In the illustrated embodiment, there is shown the perimeter tapered
shape of the tenon 11 and parallel ridge lines 42 which define a thin
strip of surface 47 that sits above larger surface 43 creating a concave
depression rather than having surface 43 same elevation as surface 47
defined by the perimeter 11 and parallel ridge lines 42. Surface 47
forming 45 degree cut or chamfered tips 50 provide more latitude for
initial engagement of tenon 11 and slot 17 as well as extra room once
tenon 11 is seated finally into deepest extent of female channel 11. This
lowered area represents the removal of material within the body of tenon
11 and provides additional space for reciprocal elevated surface 44 as
defined in the slot 17 of post bracket 5 as shown in FIGS. 5 and 7.
Surface 43 is defined further by a cavity 45 located on underside of
extension 10 and by counter bored holes 12 at more or less remote ends of
surface 43. Said holes 12 through tenon 11 permit flat head screws 19 to
sit deeply enough that they will not obstruct the mating functionality of
the rail and post brackets.

[0096] Referring to FIG. 9 is a perspective of the rail connector 4
showing the tapered tenon 11 and fasteners 19 that are seated in counter
bores 18. A counter bore hole 20 in the extension 10 accepts a fastener
21 thus locking the rail bracket 4 and post bracket 5 together when
mated. The rail bracket 4 is further defined by its "L" shape which from
a side view appears with a uniform thickness and forms a smooth flat
surface 46 at lower elevation than surfaces 43 and 47 of tenon 11.
Surface 46 continues until interrupted by perimeter juncture line 49 of
upwardly chamfered side surface 48 forming the underside of tenon 11.

[0097] FIG. 8 shows a perspective view of the back side of rail bracket 4
which is defined by a central rib 51 running the length of rail bracket 4
and intersected perpendicularly by three vertical protruding cross ribs
52 thus further defining eight cavities 53 surrounded by ribs 52, 53 and
perimeter ridge 54. Fastener holes 16 are surrounded by a cylindrical
mass of material 55 to reinforce screw hole channel 16 and remove as much
excess material as possible. The zone along the length of rib 51 is
further defined by sub-cavities 57 which are visible in six of the upper
eight cavities 53 and descend underneath top surface 43 of tenon 11.
Gripping cones 22 that impress into the end of the rail member 2 are
shown at corner locations but could also be in other locations along
central rib 51 or cross ribs 52 as desired to improve stability near
fastener holes 23 shown exiting the back side of the bracket. Thus the
gripping cones 22 provide a plurality of projections on the rear surface
of the rail bracket 4 that are sized to grip the material of the rail.

[0098] The rail bracket 4 is depicted in FIG. 22 to show greater detail of
the tapered thickness of the tenon 11 along its length. The top 34 of the
tenon 11 is the thickest and widest part and it becomes progressively
thinner as it slopes downward along its length until the bottom end 35
where it is at it thinnest and narrowest. The post bracket 5 is depicted
in a section along the longitudinal medial plane in FIG. 23 to show
greater detail of how the complementary slot 17 is also a tapered shape
along its length in this second dimensional plane. The thickest and
widest part of the slot is at the top which would represent the opening
31 and it becomes progressively thinner as it slopes downward inwards
along its length until the bottom end 33 where it is at its thinnest and
narrowest.

[0099] Referring to FIGS. 6 and 7, there is a perspective view of the back
and front of the post bracket 5. A flat surface 13 at the top edge of the
post bracket 5 allows for the extension 10 to sit flush and a screw hole
14 located in the flat surface 13 allows for a screw 21 to secure the
rail bracket 4 to the post bracket 5. The slot opening or throat 31 of
the slot 17 is defined in planar surface 13. The slot 17 narrows as it
moves down to the opposite end of the bracket 5. Surface 44 inside the
slot 17 is defined by descending and outwardly chamfered surfaces 56
which terminate at juncture of flat surfaces 57 and which mate closely
with the reverse chamfered surfaces 48 of tenon 11 as shown in FIG. 9. By
virtue of surface 44, chamfered surfaces 56 and flat surface 57 a zone of
thicker material is created around screw hole 14 when viewed from the
perspective of surface 13 thus permitting screw 21 to function properly
and safely as a means of fastening extension 10 to post connector 5.
Counter bored holes 18 are located along the center line of the surface
44 and flat surface 58 of post bracket.

[0100] Fasteners 19 are seated below the planar surfaces. It is understood
by those skilled in that art that it would also be possible to locate a
counter bore screw inside the channel 17 if desired with acceptable
performance. But it is preferable to locate fasteners as near to the ends
of the brackets as possible in order to provide greater resistance to
torsion or rotational forces that may be imposed on the rail member 2 or
post 1.

[0101] Surface 58 is further defined by eight cavities 59 located inside
peripheral walls 60 and perpendicular ribs 61. The opening in surface
area 58 is defined by edges 62 which match juncture lines 48 of tenon 11.

[0102] From viewing the back side of the post bracket 5 as shown in FIG. 6
with a similar central rib 63 running the length of post bracket 5 and
also intersected perpendicularly by three vertical protruding cross ribs
64 thus further defining eight cavities 65 surrounded by ribs 63, 64 and
a perimeter wall 66. Fastener holes 16 exiting the back are surrounded by
a cylindrical mass of material 67 to reinforce screw hole channel 16 and
remove as much excess material as possible. Fasteners 19 pass through
said hole 16. The zone along the length of rib 63 is further defined by
sub-cavities 68 which are visible in all eight cavities 65 and descend
underneath top surface 44 of slot 17. Small gripping cones 15 are shown
in the corner regions of the post connector 5 but could be located in
various locations along ribs 63 or 64. Said cones 15 are designed to
impress the post surface precisely and physically register its desired
final location. Thus the gripping cones 15 provide a plurality of
projections on the rear surface of the post bracket 5 that are sized to
grip the material of the post. At least four locator pin receptacles 40
are shown and are required so as to mate with at least two locator pins
29 on wedges 24 and 30 given the asymmetrical nature of the wedge design
which allows for only one molded part to function with the post bracket 5
when connected to opposite ends of a 2×4 rail 2.

[0103] Referring to FIG. 10 is a side perspective view of the rail bracket
4 and post bracket 5 when the tenon is slid into the slot and fully
seated. Gripping cones 15 are shown penetrating the post wall while
gripping cones 22 from the rail bracket are embedded into the end of the
rail member 2. Fasteners 19 in the post 1 are located as far apart as
possible to create the longest distance to resist torsion or rotational
forces that may be imposed at the union. The top fastener must clear the
end the vertical screw 21. Therefore the upper most location of counter
bore 18 is determined by depth of screw 14 as shown in FIG. 24. The
embossed or impressed lines 7 are set along the peripheral edges of the
mated railing connector 3.

[0104] Referring to FIGS. 11-18 are perspective views of the rail bracket
4, post bracket 5 and 22.5 degree wedge 24. References to wedge 24 also
apply to 45 degree wedge 30 in FIG. 15 which differs only in their angle.
A view of back side of wedge 24 shows gripping cones 15 at corners and
along peripheral wall 69. Said cones 15 are identified by the same
numeral as in the post bracket 5 even though in this iteration the post
bracket and wedge 24 are two independent parts. It should be understood
by those skilled in the art that the post bracket 5 and wedge 24 or 30
could be made into a single part if desired without sacrificing the
functionality of the completed railing connector 3. The interior area of
wedge 24 or 30 is defined by central rib 70 running the length of wedge
24 or 30 and intersected perpendicularly by three vertical protruding
cross ribs 71 thus further defining twelve cavities 72 with flat planar
surfaces 73 parallel to the top planar surface 68 and surrounded by ribs
70, 71 and peripheral wall 69. A unique defining feature of wedges 24 and
30 are cavities 73 which may be formed by removing material around the
walls of the fastener holes 25 or by being molded into the part.
Furthermore the four exit holes 26 for fasteners 19 are defined
integrally into central rib 70 and seen as cylindrical masses 74. Four
holes are provided so that wedge 24 or 30 will mate with the back of post
bracket 5 whether secured to either end of a 2×4 rail 2.

[0105] FIGS. 11 and 15 show counter bore holes 27 in the sides of the
wedge 24 and 30 allowing fasteners 19 to penetrate post 1 from an angle.
Flat surface 64 is defined by concave gripping cone cavities 28 to accept
the gripping cones 15 of the post connector 5. At least two cylindrical
locator pins 29 are further defined on the planar surface 68 of the wedge
that fit into receptacles 40 on the back of the post bracket 5. The
fastener holes 26 in the wedge are perfectly aligned with the holes 16
exiting the back of the post bracket 5. In addition, a person skilled in
the art will note that there are four holes 26.

[0106] This arrangement compensates for the asymmetrical positioning of
the pair of fastener holes 16 in the post bracket 5. The wedges 24 and 30
can be flipped or rotated as would occur in the field when the post
brackets are being attached at the opposite end of a top or bottom rail
37. This feature allows one wedge to be used in a left or right rail to
post connection.

[0107] Referring to FIGS. 14 and 18 are perspective views of the back side
of the wedge 24 and 30 and the gripping cones 15 and of the completed
railing connector 3 with post and rail fasteners 19 and flange screw 21.
Post bracket 5 and wedge 24 or 30 are mated together by locator pins 29,
pin receptacles 40, cones 15 and cone cavities 28 and then held tightly
together by common screw 19 passing through aligned screw holes 16 and
26.

[0108] These views show how the various components that comprise the
completed railing connector 3 can be modified with the addition of the
22.5 degree wedge 24 or 45 degree wedge 30 to create a connector capable
of joining opposing members at 45 or 90 degree opposition to one another
by bisecting the angles in half.

[0109] Referring to FIG. 19 is a top view of a common 90 degree corner
configuration to illustrate how the simplest embodiment of the apparatus
is configured to join post and rails where opposing post faces are
directly facing each other in 180 or 90 degree applications.

[0110] Referring to FIGS. 20-21 are top views of a common 45 and 22.5
degree corner configuration illustrating how the 45 degree wedge 30 and
22.5 degree wedges are used to adapt to different post orientations as
the case may be.

[0111] Referring to FIGS. 22-23 are views that provide greater detail of
how the tenon 11 tapers from thickest at the top 34 to thinnest at the
terminus of the member near the bottom 35 of rail bracket 4. The same is
observed along the length of the slot 17 where it tapers from the opening
31 which is the widest part of the slot and to the end 33 where it is
shallowest at the bottom of bracket 5.

[0112] Referring to FIG. 24 is a cross sectional top view looking down on
the slot 17 of the post bracket 5. The mating relationship is depicted at
the moment the tenon 11 is about to enter the slot 17. From this view it
can be clearly observed that because of the tapering of the tenon 11 and
slot 17 along two dimensions (thickness and width), a gap 36 and gap 41
are created at the precise and critical moment of aligning post 5 and
rail 4 brackets. Gaps 36 and 41 allows a user to simultaneously align the
tenons 11 more easily at the four remote ends of the top and bottom rails
2 in a completed rail assembly 37. Gap 36 provides additional space along
central axis (in and out movement) between tenon 11 and slot 17 while gap
41 provides similar space along lateral axis (sideways movement) at the
moment of engagement.

[0113] Referring to FIGS. 25-27 are perspective views of completed post
and rail assemblies in various stages of installation. FIG. 25 depicts a
rail assembly 37 including balusters 39 and secured rail connector
devices 3 comprised of rail bracket 4 and post bracket 5 fitted
accurately between two posts 1 and resting on spacers 38 which set the
lower rail 2 at the desired height above the surface and allowing precise
registration of post bracket 5 gripping cones 15 against each post. FIG.
26 depicts the rail assembly 37 elevated above the posts with exposed
rail brackets 4 and post brackets 5 secured in final position on posts 1
just prior to dropping rail assembly 37 in place. FIG. 27 depicts the
final resting position of the rail assembly 37 between posts.

[0114] The following emphasizes some of the aforesaid characteristics of
the device and describes the preferred method of employing it. The
preferred method will describe installing a complete assembled railing
section taking full advantage of the features of the railing connector
device 3. However it will be clear to those skilled in the art that rails
2 can be installed individually with balusters 39 connected afterwards
even though this is a slower method.

[0115] The first step is to cut two rails 2 to precise length to match the
distance between opposing post 1 faces less the total thickness of two
rail connectors 3. Rail connectors 4 are then closely aligned along the
periphery of the walls of the rail 2 and against the transverse surface
of the end of each 2×4 rail 2 and fastened with screws 19 that pass
through counter bored holes 12 in the inner contoured body of the tenon
11. This is made easy by virtue of gripping cones 22 located on the rear
planar surface of the connector 4. They are small but long enough to
impress into the end grain of soft to mid density wood fiber. This
ensures that the connector maintains its location while driving the screw
19 even if it begins to try to follow a grain line in the wood. Precisely
driving screws parallel to the grain is more difficult than in a cross
grain direction as screws can drift and follow the interface between
grain rather than cutting through and maintaining an original trajectory.
The gripping cones resist this force and keep the screw tracking
correctly in line with the original position of the connector. In order
for the two separated parts to re-align perfectly they must not move
while screws are being fastened.

[0116] The next step is to slide the post connectors 5 together with the
rail connector 4. This is done by aligning the tenon 11 of the rail
bracket above the throat 31 of the slot 17 of the post bracket 5 and
pushing the pieces together until the tenon and slot fully engage and the
overlapping horizontal extension 10 of the rail connector sits flush over
top the flat surface 13 of the post connector 5. This is followed by
attaching a series of balusters 39 to each rail 2 to create a rail
assembly 37.

[0117] The rail assembly 37 with rail connectors 3 secured to the ends of
each rail 2 is then fitted between opposing posts 1 and set onto spacers
38 which set the rail assembly 37 at the desired height above the
surface. The rail assembly 37 is intended to fit between the posts 1 with
a close tolerance such that once rested on the spacers 38 an installer
can easily press each post connector 5 firmly against the post 1 face
forcing the gripping cones 15 to leave a physical depression in the wood
thus precisely registering the final location where each post connector 5
will be secured. In addition, the impression lines 7 can be used to mark
the center lines of the post connector 5 against the post with a pencil.
Using a pencil would be more suitable for installations where the post
material is sufficiently dense that the gripping cones 15 are not able to
register their locations or only faintly so. With very hard material it
may be necessary to cut the cones off with a knife blade prior to fitting
the assembly between the posts.

[0118] Once the exact locations of the four post connectors 5 are marked
on the posts 1, the rail assembly 37 can be removed from between the
posts 1 and the post connectors 5 can be slid apart from the rail
connectors 4 and placed in exact position on each post 1 as indicated by
the physical depressions or pencil markings. The cones 15 fit easily in
the depressions and let the installer know that the connector 5 is seated
in precise location before driving screws 19 and securing the connector
5. The gripping cones 15 hold the post connectors 5 in place and stop
them from moving while the screws 19 are driven through fastener holes 16
and seated fully into the counter bores 18 within the slot 17 in the body
of the post connectors 5. The counter bores 18 are sufficiently deep so
as to ensure the heads of the screws 19 are below the planer surface of
the slot 17. The importance of the precise location of the post
connectors 5 on the posts 1 and the depth of the top of the screw heads
within the counter bores 18 will become apparent in the following steps.

[0119] When the post connectors 5 have been accurately secured to opposing
posts 1, the rail assembly 37 which has rail connectors 4 secured to the
ends of each rail member 2 is re-aligned between posts above the throat
31 of each slot 17 in the post connector 5. Each tenon 11 is slid into
the corresponding slot 17 until fully seated and the parts are mated. A
small screw 21 is then installed through the counter bored hole 20 in the
overlapping extension 10 of the rail connector 4 and embedded into a hole
14 in the body of the post connector 5 thus preventing any vertical
uplift of the connectors. In normal use of a rail or fence, no upward
forces are usually experienced but this securing technique ensures it is
not possible to pull the connectors apart from upward forces.

[0120] The tapered shape of the tenon and slot in two dimensions--from
wide to narrow across the width and from thicker to thinner along the
length--provides very user friendly functionality for a user working
alone to install rail assemblies. When the mating connectors are
positioned above each other just prior to engagement, the narrower tip 35
at the bottom of the tenon 11 on the rail connector 4 has additional
clearance 36 to enter the wider throat opening 31 at the top of the slot
17 on the post connector 5. This allows a user a greater degree for
margin of error during the critical alignment and simultaneous insertion
of four remote tenons 11 into the corresponding slots 17. As the
connectors slide together, the clearance between the tenons and slots
gradually decreases until it is all together eliminated and the parts fit
snuggly and precisely together.

[0121] Because of the nature of the device 3 and how all four post
connectors 5 can be so accurately located on to a post surface as to mate
with the reciprocal rail connector 4, a precise fit is greatly enhanced
in each installation of a railing section. Furthermore the tapered shape
of the tenon 11 and slot 17 permits a wide margin of forgiveness at the
moment of simultaneously aligning the four independent mating sections of
the connectors. This makes for an easier and more pleasant installation
procedure as the parts literally pull themselves into a tighter
connection as they slide together.

[0122] This rail connector 3 can be modified to work with different corner
angles. A 22.5° wedge 24 and a 45° wedge 30 can be fitted
together securely into the back side of the post connector 5. When
installing the rail connector with either of the wedges 24 and 30
depending the on the desired angle, the locator pins 29 of wedge 24 are
fitted into pin receptacles 40 of post bracket 5. The assembly of wedge
24 and post bracket 5 is now used in the same methodology as previously
described for the post bracket 5 and rail bracket 4. That is to say,
rails must be cut to precise length equal to the distance between the
faces of opposing angled posts measured from the vertical center line of
each post face less the total thickness of two of the conjoined rail
connectors 3 comprised of post bracket 5, rail bracket 4 and wedge 24 or
30 as the case may be.

[0123] Thickness of the wedges 24 or 30 for purposes of subtraction, are
measured from opposing edges of wedge 24 or 30 and rail bracket 4 and
along the center line of the conjoined rail connector 3 by using the
center impression lines 7. The rail brackets 4 can then be screwed to the
ends of each 2×4 rail as part of a completed rail assembly 37. Rail
assembly 37 may then be set on spacers 38 between opposing rail posts 1
such that the gripping cones 15 on the back of wedges 24 or 30 can be
depressed into each post face with modest pressure registering physical
depressions of exact desired location. The assembly 37 can then be pulled
away from the posts 1, wedge 24 or 30 and post bracket separated from
each rail connector 4 then and located exactly on each post 1 by aligning
cones 15 with each of the cone depressions. Screws 19 are then used to
fasten the wedge 24 or 30 and post bracket 5 through the holes 15 and 25.
The rail assembly 37 can now be lowered into place by sliding tenon 11
and slot 17 together and screw 21 through extension 10. This is repeated
for the three other remote ends of the remaining 2×4 rails.

[0124] While embodiments of the invention have been described and
illustrated, such embodiments should be considered illustrative of the
invention only. The invention may include variants not described or
illustrated herein in detail. Thus, the embodiments described and
illustrated herein should not be considered to limit the invention as
construed in accordance with the accompanying claims.